Electrical connection means



Dec. 31, 1940. H, A DOUGLAS 2,226,849

ELECTRICAL CONNECTION MEANS Original Filed July 3. 1936 W 75j :e35- f ly.

.ATTORNJEXS Patented Dec. 31, 1940 ATENT ortica ELECTRICAL CONNECTIONMEANS Harry A. Douglas, Bronson, Mich., assgnor to Kingston ProductsCorporation, a corporation of Indiana Application July 3,1936, serialNo. 88,854 Renewed November 20, 1939 11 Claims. (C1. 173-269) Thisinvention relates to electrical connection means, more particularly tomeans for'connecting a plug conductor terminal to an electricalconductor, and the principal object of this invention is to provide newand improved electrical connection means of these types.

In the drawing-accompanying this specification.

and forming a part'of this application, I have shown, for purposes ofillustration, several forms which my invention may assume, and in thisdrawing: y

Figure 1 is an elevationalV view disclosing one embodiment of theinvention in operative relation'with a receptacle of the so-called snaptype.

Figure 2 is a longitudinal sectional view of the embodiment,illustrating a stage of assembly,

Figure 3 is alongitudinal sectional view of the embodiment as completelyassembled, and further illustrating, in removed relation, one of aseries of jaws for effecting connection,

Figure 4 is an enlarged transverse section corresponding to the line 4-4of Figure 3, and also showing two of a series of jaw members foreffecting one connection,

2 Figure 5 is an enlarged transverse section corresponding to the line 55 of Figure 3, and showing two of a series of jaw members for effectinganother connection,

Figure 6 is an enlarged transverse sectional view corresponding to theline 6--6 of Figure 3,

and showing two of aA series of jaw members for effecting still anotherconnection, and

Figure '7 is a longitudinal sectional view disclosing another embodimentof this invention.

Referring particularly to Figures 1 through 6, the embodiment of theinvention therein shown comprises a body II, preferably formed ofsuitable electric current conducting material. The body I I may beshaped to provide a plug conductor terminal of the snap type, and tothis end the body II is preferably provided with a gen` erallycylindrical portion I2, having an annular furrow I3 formed therein. Thecylindrical 45 portion I2 at one end merges with a frustro-conical noseportion I4, and at its other end merges with an enlarged generallycylindrical portion I5. The body I I may be provided with a recess, andas preferred and shown in Figure 2, the body II is 50 axially bored, asat I6, the bore I6 extending inwardly from the enlarged portion I5, andstopping short of the extremity of the nose portion I4. Adjacent theenlarged cylindrical portion, the bore I6 is counterbored as shown atI'I, to form this 55 vcylindrical portion into generally sleeve shape.

The bore IB and the counterbore II are preferably joined by a taperingportion, as shown at I8 in Figure 2. If desired, the enlargedcylindrical portion I5 may be provided with a anged extremity I9. kAninsulated electrical conducting member 20 is adapted to be disposedwithin the axial recess formed inthe body II, and comprises an innercore 2| of current conducting material, prefer- `ably stranded wire asshown, and an outer cov- 10 ering 22 of insulating material, such as acovering of rubber about the core 2l, followed by a covering of fabricabout the. rubber covering. However, it will be understood that thecovering u 22 may be all rubber, or any other suitable insulatingcovering which may be preferred. As best shown in Figure 2, theinsulation is stripped from one end of the member 20, to provide a baredportion 23, and that end of the member 20 is then threaded into theaxial recess in the body II, so 20 that the bared portion 23 is disposedin the bore I6, and the adjacent insulated portion is disposed in thecounterbore Il. The shoulder formed by stripping the insulation from theconducting member may abut the Wall of the tapered portion I8, as shownin Figure 2, so as to serve as a suitable means for limiting insertionof the member 20, although it will be appreciated that the taperedportion 'I8 provides a recess for receiving any frayed part of theinsulation, so lthat this 30 frayed part cannot prevent proper insertionof the bared portion 23 of the conductor member 2li. It will also beobvious that abutment of the end of the bared portion 23 with the-closedend of the. bore I6 may serve as a means for limiting insertion .35 ofthe member 20. As shown in Figure 2,- the transverse size of theinsulating covering 22 need not snugly t within the counterbore I1,thereby providing for the accommodation of various sized members 20. o

To secure the body II vto the insulated conductor member 20, the body'isprovided with suitable indentations disposed in spaced planes generallytransverse to the common axis of the bore I6 and counterbore I1. As bestshown in Figure 3,

- the body ispreferably secured to the bared portion 23 by means of a.swedging action produced by a plurality of jaws 24, each of whichcarries j-aw members 25, 26, and 21, suitable for the swedging purposes.In this embodiment it is preferred to use four jaws 24, although it beunderstood thatl any other number of jaw members maybe used.

. As shown in Figure 3, each jaw member' 25, 55

in longitudinal section, comprises a relatively narrow rectilinearprojection extending from the jaw 24. The wall dening the length of thejaw member 25 cooperates with the extending walls of the jaw member toform relatively sharp cutting edges 26. A transverse section through twoof the jaw members 25 is best shown in Figure 4, wherein it isillustrated that each of the jaw members 25 is contoured to cusp-likeshape, as shown at 29. The jaw member 26 is shaped similar to the jawmember 25in that it provides relatively sharp cutting edges 30, and thejaw member 26 is spaced from' the related jaw member 25, as shown inFigure 3. Each of the jaw members 26 is contoured to cusp-like shape,as'

shown at 3l in Figure 5. Spaced from the jaw member 26 is the jaw member21, and each member 21 comprises an extension of the jaw 24, the

extension having side walls 32, as shown in Figure 6, tapering towards areentrant or concave limiting wall 33. Each of the jaw members 21, atthe limiting wall 33, is shaped to provide a relatively sharp cuttingedge 34, and a rounded edge 35 (Figure 3).

To assemble-the body II with the insulated conductor member 20, thelatter member is disposed within the bore I6 and counterbore I1, ashereinbefore described, and with the bared por,- tion 23 positionedwithin the axial bore I6, as shown in Figure 2. 'I'he body II issuitably positioned in a holding device (not shown) which also includesmeans for moving the four jaws 24 simultaneously toward the axis of thebody II, and for positioning each jaw 24 so that the jaw members 25, 26,and 21 are in registry respectively with the frustro-conical nose I4,the cylindrical portion I2, and the sleeve portion I5. When the fourjaws 24 are moved toward the axis of the body II, the cusp-like portions29 and 3I of the jaw members 25 and 26, and the surfaces adjacent thelimiting wall 33 of the jaw.

member 21 will be pressed into the adjacent surfaces of the body II.After the jaw members 24 have been moved toward the axis of the body IIa predetermined amount, the jaws 24 are returned to spaced position withrespect to the body II.l

A transverse section through the indentations produced by the jawmembers 25 is shown in Figure 4, and inspection of this gure willdisclose that the jaw members 25 produce four indentations 36.1n thenose portion I4 ofthe body II, the indentations being similar in lshapeto the contour of the jaw members 25. It will further be noted that thepressure exerted by the jaw members 25 has been transmitted through thematerial of the nose portion I4 to the adjacent bared portion 23 of theconductor member 20, so that this portion, in line with the indentations36, has been pressed from its generally circular shape to a shapesimilar to a poly-- gon with reentrant sides, as best shown in Figure 4.Furthermore, this pressing or swedging action of the jaw members 25 hascaused the strands of thebared portion to be pressed tightly together tosubstantially integral condition, and in addition, this integralportionof the bared portion 23 is pressed to have substantially integralrelation with the adjacent surface of the nose portion I4. Therefore, itwill be apparent that a substantially solid metal to metal connection iseffected between the bared portion 23 of the conductor member 20, andthe nose portion I4 0f the body II.

A transverse section through the indentations produced by the jawmembers 26 is best shown in Figure 5, wherein it is illustrated that thejaw members 26 produce four indentations 31, similar to the indentations36, and corresponding in shape to the contour of the jaw members 26. Asbefore, the pressure exerted by the jaw members 26 has been transmittedthrough the material of the cylindrical portion I2 to the adjacentbaredportion 23 of the conductor` member 20, so that this adjacent portionhas been pressed from its circular shape to a shape similar to thatdescribed in connection with the indentations produced by the jawmembers 25, and this swedging action 'of the jaw members 26 causes thestrands of the adjacent part of the bared portion to be pressed tightlytogether to substantially integral condition, and in addition, thisintegral portion is pressed to have substantially integral connectionwith the adjacent cylindrical portion I2. Therefore, the connections sofar described provide axially spaced, substantially solid metal to metalconnections between the body portion I I and the inner core 2l of theconducting mem ber 20.

'I'he indentations formed by the jaw members 21 are best illustrated inFigures 1, 3, and 6. These indentations 38 areproduced by the inwardmovement of the jaw members 21, this inward movement causing the sharpedge 34 to cut into the sleeve I5, the rounded edge 35 pressing theadjacent portions of the sleeve I5 inwardly into the insulating cover 22ofv the conductor member 20 so las to rmly engage with the insulatingcovering 22. This pressing action will also cause the portion of thestranded wire transversely in alignment with the indentations 38 to besomewhat compressed as best shown in Fig-- ure 3. It will be apparentthat part of the indentation produced by the rounded edge 35 of the jawmember 21 will be curved as shown at 39 in Figure`3, so that the freepart of the conductor member 20 may be moved laterally without frayingor cutting the insulating covering 22. As best shown in Figure 1, thejaw member 21 causes the adjacent surfaces of the sleeve I5 to bendinwardly as at 40, and also, the flange I9 is caused to pucker as at 4I.As best shown in Figure 6, the indentations 38 form the sleeve portionI5 so as to provide curved surfaces 42 corresponding to the limitingwalls 33 of the jaw members 21. Intermediate the curved surfaces 42, thejaw members 21 form petal-like portions 43, which have their outerextremities generally aligned with the original periphery of the sleeveportion I5, the walls oi' the petal-like portions 43 tapering towardsand merging with the curved surfaces 42. It will be obvious that thepressure of the jaw members 21 causes at least some of the insulatingcovering 22 to occupy spaces between the walls of the petal-likeportions 39, as shown at 44. Also, some of the insulating covering 22 isdisplaced and pressed into the tapering recess I8 intermediate the boreI6 and the counterbore I1, as shown at 45 in Figure 3.

From the foregoing description it will be obvious that the body portionII has three connections with the conducting member 20, two of theseconnections providing substantially solid metal to metal contact betweenthe body portion II and the conducting core 2|, and the third connectionproviding connection between the sleeve I5 of the body II and theinsulating cover 22 of the conducting member 20. With this contionformed in the cylindrical portion I2. Furthermore, the connection formedby the indentations 31 in the cylindrical portion I2, is substantiallysealed from communication with the exterior of the body II by theconnection formed by the indentation 38 in the sleeve portionv I5.Therefore, no corrosive substances can enter the axial bore I6, and as aconsequence, the

electrical connections formed by the indentations 36 and 31 will not besubjected to corrosive action, and these connections will provideperfect electrical connection between the body I I and the core 2l underall conditions. The connection formed by the indentations '38, inaddition to its sealing function, also serves the purpose of taking upstrains produced by forces which may be applied to the conductor member20 during assembling operation with a suitable receptacle.

.It will be obvious that any two of the three connections described maybe used to satisfy certain predetermined conditions, and also, moreconnections than just the three described may be used without departingfrom the spirit of the invention.

use with a receptacle 46. The receptacle 46 may be of any suitableconstruction, but preferably comprises a solid portion 41 adapted forconnection to a support 48 in any suitable manner. The solid portion 4'Iis provided with a transverse bore 49, which communicates,I through anaperture 50, with a longitudinally bored portion 5I of the receptacle46. A detent member 52 is disposed within the bore 5I, and has a portionextending through the aperture 50 and into the transverse bore 49, and aspring 53 is interposed between the detent member 52 and an inturnedflanged part of the bored portion 5I of the receptacle 46, to yieldablyurge the detent member to operative position.

In operation, the plug conductor body II is inserted withinthetransverse bore 49 of'the receptacle 46, the frustro-conical nose I4 ofthe plug body II camming the detnt member 52 inwardly of the boredportion 5I to permit .passage of the cylindrical part I2 of the plugbody I I. When the furrow I3 of the plug body II is disposed adjacentthe detent member 52, the latter member -will snap into the furrow I3and mechanically and electrically hold the plug body 'conductor member20, this pulling force causing the walls of the furrow I3 to cam thedetent member 52 inwardly so as to provide for the passage tion, saidterminal and said bare part being of the cylindrical part I2 of the plugbody I I.

Referring to Figure 7, lthe embodiment therein shown comprises a bodyIla similar to the body II. As in the .case of the embodiment shown inFigures 1 through 6, electrical connection between the body Ila and theconductor member 20a is veiected byindentations 36a and 31a'. In thisinstance, however, indentations 54 are formed in the sleeve I5a, theseindentations 54 being substantially similarto. the indentations 38 ofthe embodiment shown in Figures l throughG, with the exception that theindentations 54 are pressed entirely through the insulating covering andinto intimate contact with the current conducting portion 2|a of theconductor member 20a. If desired, the pressing force may be great enoughto produce substantially solidl metal to metal connection between thebaredportion 23 andthe adjacent portion of the indentations, similar tothe connections vproduced by the indentations 36a and 31a. v'I'heconstruction of this embodiment provides three electrical connectionsbetween the body I Ia. and the conductor member 20a, and also providesconnection to the insulating covering to take up stresses as beforedescribed.

From the foregoing it will be apparent to those skilled in the art thatthe illustrated embodiment of my invention provides new and improvedelectrical connection means, readily and conveniently constructed andassembled, and accordingly, accomplishes at least the principal objectof my invention. On the other hand, it also will be obvious to thoseskilled in the art that the illustrated embodiment of my invention may4only, and my invention is not limited thereto.

1. An electrical connection, comprising: an insulatedelectricalconductor, the insulation on said conductor terminating short of the endof the conductor, leaving the end portion of the conductor bare; 'aterminal, for said conductor, including an elongated body having alongitudinal recess closed at one end and open at the other andotherwise imperforate, said recess receiving the bare part of saidconductor and the adjacent end portion of the insulation, said terminaland.

said bare part being swaged into a continuous electrical' connectionwithin and about said recess, and said terminal and said insulationbeing swaged together into a continuous connection sealing the open endof said recess and preventing -corrosive substances from reachingsaidelectrical connection, said last-mentioned swage having curved portionsconforming substantially to first portion receiving the bare part ofsaid con-l ductor, and having an enlarged entrance portion forming ashoulder between said enlarged portion and said iirst portion, saidenlarged portion receiving the adjacent end portion of the insulaswagedat least three places spaced apart circumferentially in a common generalplane transverse to said terminal into a continuous electricalconnection within and about said recess, and saidterminal and saidinsulation being swaged together into a continuous second connectionsealing the open end of said recess and preventing corrosive substancesfrom reaching said electrical connection, said second connectionincluding in- `sulation forced towardL said first portion of said recessagainst said shoulder, the swage at said second connection having spacedapart curved portions defining the outline of.a circle, the di.

ameter of which is-less than the outside diameter of said insulation.

f 3. An electrical connection, including members determined transversegeneral plane on one side Y of said groove; said conductor means andsaid` l5 sleeve also being swaged into a continuous solidmetalcross-section in a predetermined transverse general plane on the otherside of said groove adjacent the closed end of said sleeve and saidskirt being crimped to bring the sleeve and 20 insulation on theconductor into bearing relation whereby to substantially close saidannular space and in conjunction with said closed end substantially sealfrom the atmosphereV at least one of said swaging planes.

25 4. An electrical connection, including members united inV swagedrelation; said members comprising insulated metallic conductor means anda grooved sleeve having a closed end, and an open end in which a bareend of said conductor means 30 is disposed; a skirt provided on saidsleeve receiving the insulation in a manner to provide an annular spacebetween the skirt and the insulation; said conductor means and saidsleeve being swaged into a solid-metal cross-section in a pre- 35determined transverse general plane on one side of said groove betweenthe groove and said skirt;

said conductor means and said sleeve also being f swaged into acontinuous solid-metal cross-section in a predetermined transversegeneral plane 4o on the other side of said groove; and said skirt beingcrimped to bring the sleeve and insulation on the conductor into bearingrelation whereby to close said annular space and in conjunction withsaidclosed end substantiallyseal from the 45 atmosphere atleast two o!said swaging planes.

5. An electrical connection, including members united in swagedrelation; said members comprising insulated metallic conductor means anda grooved sleeve having a closed end, and an open 50 end in which a bareend of said conductor means is disposed; a skirt provided on said sleevereceiving the insulation in a manrur to provide an Y annular spacebetween the skirt and the insulation; said conductor means .and saidsleeve being 55 swaged into a solid-metal cross-section in apredetermined transverse general plane on one side of said groove;l saidconductor means and said sleeve also being swaged into a continuoussolidmetal cross-section in a predetermined-trans- `u() verse generalplane on thelother side ci.' said groove adjacent the closed end ofsaidsleeve; and said skirt having crimpings bringing the sleeve andinsulation on the conductor into bearing relation whereby tosubstantially close said annular 65 space and in conjunction with saidclosed end substantially seal` from the atmosphere at least one of saidswaging planes; said crimpings being sleeve having a closed end and atleast three swaged indentations spaced circumferentially in a commonplane transverse to said sleeve; said sleeve also having at least threeswaged indentaticns spaced circumiferentially in a common gen- 5 eralplane transverse to said sleeve and in spaced apart relation to saidrstmentioned plane; and said conductor means and said sleeve havingsubstantially. a continuous solid-metal cross-section in said planes. v

'7.` An electrical connection, comprising: an insulated electricalconductor, the insulation on said conductor terminating short of the endof the conductor, leaving' the end portion of the conductor bare; aterminal. ior said conductor, including an elongated body having a landportion and a skirt portion and a longitudinal recess closed at one endand open at the other and otherwise imperforate, said'recess adjacentsaid land portion receiving the bare part of said conductor, said'recess being enlarged at the skirt portion and receiving the adjacentend portion of the insulation, said terminal and said bare part adjacentsaid land being swaged into a continuous electrical connection within`and about said recess, and said terminal and said insulation adjacentsaid skirt being swaged together into a continuous connection sealingthe open end of saidrecess and assisting to prevent corrosive substancesfrom reaching said electrical connection, said last-mentioned swagehaving curved portions conforming substantially to the curvature of theinsulation.

8. An electrical connection, comprising: an insulated 'electricalconductor, the insulation on 35 said conductor terminating short of theend of the conductor, leaving the end portion of the conductor bare; aterminal, for said conductor, including an elongated body having a landpor- .'tion and askirt portion and a longitudinal re- 40 cess closed atone end and open at the other and otherwise imperforate, said recesshaving a first portion substantially within the land for receiving thebare part of y said conductor, and having an enlarged entrance portionsubstantially within the skirt forming a shoulder between said enlargedportion and said rst portion, said enlarged portion receiving theadjacent end portion of the insulation, said terminal and said bare partadjacent said land being swaged at least three places spaced apartcircumferentially in a common general plane transverse to said terminalinto a continuous electrical connection within and about said recess,and said terminal and said insulation adjacent said skirt being swagedtogether into a continuous second connection substantially sealing theopenI end of said recess and assisting to prevent corrosive substancesfrom reaching said electrical connection, said second connectionincluding insulation forced toward said rstI portion of said recessagainst said shoulder, the swageoat said second connection having spacedapart Icurved portions defining .the outline of a circle, the diameterof which is less than the outside diameter of said 85 insulation. Y

9. An electrical connection, including mem-` -bers united inswagedrel-ation; said members comprising' insulated metallic conductormeansl and a sleeve having an' abutment, a closed end, 70 and an openend in which a bare end of said conductor means 'is disposed; a skirtYprovided on said sleeve receiving the insulation in a manner to providean annular space between the skirt and the insulation; said conductor`means A eral plane on one side of said abutment; said conductor meansand said sleeve also `being swaged into a continuous solid-metalcross-section in a predetermined transverse general 4plane on .the otherside of said abutment; and said skirt being crimped to bring the sleeveand insulation on 'the conductor into bearing relation whereby tosubstantially close said annular space and in conjunction with saidclosed end substanv tially seal from the atmosphere at least one of saidswaging planes.

10. An electrical connection, including members united in swagedrelation; said members comprising insulated metallic conductor means anda sleeve having an abutment, a closed end, and an open end in which abare end of said conductor means is disposed; a skirt provided on saidsleeve receiving the insulation in a manner to provide an annular spacebetween the skirt and the insulation; said conductor means and saidsleeve being swaged into a solid-metal crosssection inl a predeterminedtransverse gener-al plane on one side of said abutment; said conductormeans and said sleeve also being swaged into -a continuous solid-metalcross-section in a predetermined transverse general plane on the otherside of said abutment adjacent the closed end of said sleeve; and saidskirt having crimpings bringing .the sleeve and insulation onl theconductor into bearing relation whereby to substantially' close saidannular space and in con- 'junction with said closed end substantiallyseal from the atmosphere at least one of said swag- `\ing planes; saidcrimpings being located back from the free end of the skirt whereby topermit the conductor under certain conditions to ilex slightly withinthe confines ot the skirt.

11. An electrical connection, including members united in swagedrelation; said membersI comprising insulated metallic conductor meansand a sleeve in -which said conductor means is disposed; said sleevehaving a closed end and at least three swaged indentations spacedcircumferentially in a common plane transverse to said sleeve; saidsleeve also having at least three swaged indentations spacedcircumferentially in a common general plane transverse to saidsleeve andin spaced apart relation to said rst mentioned plane, said conductormeans and said sleeve having substantially a continuous solidmetalcross-section in said plane; said sleeve further having a portionreceiving the insulation on said conductor; and said portion beingcrimped with respect to said insulation, v

HARRY A. DOUGLAS.

